Electrode cutting device and stacked cell manufacturing device

ABSTRACT

An electrode feed unit includes an electrode plate feed unit, and the electrode plate feed unit includes an electrode cutting unit arranged to cut a conductive sheet into electrode plates by a certain length. The electrode cutting unit includes a fixed blade having a fixed cutting blade extending in a direction crossing a conveyance direction of the conductive sheet, a rotary blade of a disk shape having a rotary cutting blade on the radial outer edge, and a rotary blade moving unit arranged to rotate and move the rotary blade along the fixed blade in a state where the rotary cutting blade maintains contact with the fixed cutting blade.

TECHNICAL FIELD

The present invention relates to an electrode cutting device and astacked cell manufacturing device.

BACKGROUND ART

As batteries for vehicles or electronic devices, or other variousbatteries, a stacked type battery is widely adopted, in which negativeelectrode plates and positive electrode plates are alternately stackedwith a separator therebetween. JP-A-2014-165055 describes a structure inwhich a positive electrode plate transfer head and a negative electrodeplate transfer head alternately press the separator to fold it in azigzag manner, and transfers the positive electrode plate to the foldedseparator from the positive electrode plate transfer head, whiletransfers the negative electrode plate to the folded separator from thenegative electrode plate transfer head, so that the positive electrodeplates and the negative electrode plates are alternately stacked with aseparator therebetween.

LIST OF CITATIONS Patent Literature

Patent Document 1: JP-A-2014-165055

SUMMARY OF THE INVENTION

Technical Problem

When cutting a conductive plate so as to make positive electrode platesand negative electrode plates having high shape accuracy with a die, itis necessary to use a high accuracy die. In addition, it is necessary toreplace the die after manufacturing a certain amount of them. Inaddition, it is possible to cut using a laser, but it may be difficultto obtain the positive electrode plates and the negative electrodeplates with high accuracy because of degeneration of the cut metal plateor finely scattered material.

Accordingly, it is an object of the present invention to provide anelectrode cutting device that can stably cut high quality electrodeswith a simple structure, and a stacked cell manufacturing device thatcan stably manufacture high quality stacked cells with a simplestructure.

Means for Solving the Problem

In order to achieve the object described above, an electrode cuttingdevice according to the present invention includes a fixed blade havinga fixed cutting blade extending in a direction crossing a conveyancedirection of a conductive sheet, and a rotary blade of a disk shapehaving a rotary cutting blade on the radial outer edge, the rotary bladebeing rotated and moved along the fixed blade.

With this structure, the rotary cutting blade of the rotary blade is setwith a certain accuracy with respect to the fixed cutting blade of thefixed blade, so that the conductive sheet can be cut. In this way, theelectrode cutting unit can be simplified. In addition, when replacingthe fixed blade or the rotary blade, it is sufficient to secure acertain attachment accuracy, and the replacement is easy. Despite ofthis simple structure, high quality electrodes can be cut stably.

In the structure described above, the rotary blade rotates and movesalong the fixed blade in a state where it maintains contact with thefixed blade.

In the structure described above, the rotary blade is applied with aforce to press toward the fixed blade.

In the structure described above, a feed amount of the rotary blade withrespect to the fixed blade and a rotation speed of the rotary blade arevariable.

In the structure described above, when cutting of the conductive sheetis finished, the rotary blade is idled, and an idle rotation angle ofthe rotary blade is variable for every set number of cutting.

The structure described above further includes a first conveying rollerunit disposed on the upstream side of the rotary blade and the fixedblade in the conveyance direction of the conductive sheet, and a secondconveying roller unit disposed on the downstream side of the same. Eachof the first conveying roller unit and the second conveying roller unitgrabs the conductive sheet in the thickness direction, and applies acertain tension to the conveyed conductive sheet in the conveyancedirection. When cutting the conductive sheet by the rotary blade and thefixed blade, conveyance of the conductive sheet is stopped, and thetension of the conductive sheet at a part between the first conveyingroller unit and the second conveying roller unit is varied with respectto the conveying tension.

In the structure described above, when cutting the conductive sheet, thefirst conveying roller unit is stopped, and after a certain timeelapses, the second conveying roller unit is stopped.

In the structure described above, when cutting the conductive sheet, thefirst conveying roller unit and the second conveying roller unit areboth stopped, and then the second conveying roller unit is rotated by acertain amount in the opposite direction to the conveyance direction ofthe conductive sheet.

The structure described above further includes a notch forming unitarranged to form notches on both ends in the width direction of theconductive sheet, so as to support a part to be cut by the electrodecutting unit. The notch forming unit includes a notching mold that formsthe notches in the conductive sheet and can move in the width direction,and an edge detector disposed on the upstream side of the notching moldin the conveyance direction of the conductive sheet so as to detect anedge of the conductive sheet in the width direction. Further, thenotching mold is moved so that the notch is accurately formed at theedge of the conductive sheet in the width direction, based on the edgeof the conductive sheet detected by the edge detector.

In order to achieve the object described above, a stacked cellmanufacturing device of the present invention manufactures a stackedcell in which, electrode plates to be negative electrode plates andelectrode plates to be positive electrode plates are alternatelydisposed and stacked in valley fold parts of a bellows-shaped foldedseparator. The stacked cell manufacturing device includes a separatorfeed unit having a separator roller to feed the separator in a tapeshape, a folding unit arranged to fold the separator fed from theseparator roller in a bellows shape, and an electrode feed unit arrangedto feed the negative electrode plates and the positive electrode platesalternately to the separator folded in the bellows shape by the foldingunit. The electrode feed unit includes two electrode plate feed units.One of the electrode plate feed units is disposed on one side so as tofeed the electrode plate to be the negative electrode plate, while theother electrode plate feed unit is disposed on the other side so as tofeed the electrode plate to be the positive electrode plate. Each of theelectrode plate feed units includes an electrode cutting unit that cutsthe conductive sheet into the electrode plates by a certain length. Theelectrode cutting unit includes a fixed blade having a fixed cuttingblade extending in a direction crossing a conveyance direction of theconductive sheet, a rotary blade of a disk shape having a rotary cuttingblade on the radial outer edge, and a rotary blade moving unit thatrotates and moves the rotary blade along the fixed cutting blade.

With this structure, the rotary blade is moved while being rotated sothat the conductive sheet is cut. The rotary cutting blade of the rotaryblade is set with respect to the fixed cutting blade of the fixed bladewith certain accuracy, and the conductive sheet can be cut. In this way,the electrode cutting unit can be simplified. In addition, also whenreplacing the fixed blade or the rotary blade, it is sufficient tosecure a certain attachment accuracy, and the replacement is easy.Despite of this simple structure, high quality stacked cell can bemanufactured stably.

In the structure described above, the rotary blade moving unit rotatesand moves the rotary blade along the fixed cutting blade in a statewhere contact between the rotary cutting blade and the fixed cuttingblade is maintained.

The structure described above further includes a biasing unit thatapplies a force to press the rotary blade toward the fixed blade.

In the structure described above, a feed amount of the rotary blade withrespect to the fixed blade and a rotation speed of the rotary blade arevariable.

In the structure described above, when cutting of the conductive sheetis finished, the rotary blade is idled, and an idle rotation angle ofthe rotary blade is variable for every set number of cutting.

In the structure described above, the electrode cutting unit includes afirst conveying roller unit disposed on the upstream side of theelectrode cutting unit in the conveyance direction of the conductivesheet, and a second conveying roller unit disposed on the downstreamside of the same. Each of the first conveying roller unit and the secondconveying roller unit grabs the conductive sheet in the thicknessdirection and applies a certain tension to the conveyed conductive sheetin the conveyance direction. When cutting the conductive sheet, theelectrode cutting unit stops conveyance of the conductive sheet, andvaries the tension of the conductive sheet at a part between the firstconveying roller unit and the second conveying roller unit with respectto the conveying tension.

In the structure described above, when cutting the conductive sheet, theelectrode cutting unit stops the first conveying roller unit, and aftera certain time elapses, it stops the second conveying roller unit.

In the structure described above, when cutting the conductive sheet,after both the first conveying roller unit and the second conveyingroller unit stop, the electrode cutting unit rotates the secondconveying roller unit by a certain amount in the opposite direction tothe conveyance direction of the conductive sheet.

The structure described above further includes a notch forming unitarranged to form notches on both ends in the width direction of theconductive sheet, so as to support a part to be cut by the electrodecutting unit. The notch forming unit includes a notching mold that formsthe notches in the conductive sheet and can move in the width direction,and an edge detector disposed on the upstream side of the notching moldin the conveyance direction of the conductive sheet so as to detect anedge of the conductive sheet in the width direction. Further, thenotching mold is moved so that the notch is accurately formed at theedge of the conductive sheet in the width direction, based on the edgeof the conductive sheet detected by the edge detector.

Advantageous Effects of the Invention

According to the present invention, it is possible to provide anelectrode cutting device that can stably cut high quality electrodeswith a simple structure, and a stacked cell manufacturing device thatcan stably manufacture high quality stacked cells with a simplestructure.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a schematic layout diagram of a stacked cell manufacturingdevice according to the present invention.

FIG. 2 is a functional block diagram of the stacked cell manufacturingdevice.

FIG. 3 is an exploded perspective view illustrating an outline of astacked type battery.

FIG. 4 is an enlarged perspective view of a folding unit.

FIG. 5 is a schematic layout diagram of an electrode feed unit.

FIG. 6 is a perspective view of a notch forming unit.

FIG. 7 is a perspective view of an electrode cutting unit.

FIG. 8 is a perspective view illustrating a layout of a standby tableand a position adjusting table.

FIG. 9 is a layout diagram of a stacked cell separating unit.

FIG. 10 is a flowchart illustrating a position adjusting operation ofelectrode plates.

FIG. 11 is a perspective view illustrating a state where a firstconveying unit holds the electrode plate on the standby table.

FIG. 12 is a perspective view just after the electrode plate is placedon the upper surface of the position adjusting table.

FIG. 13 is a perspective view illustrating a state where the firstconveying unit is moving to fetch the electrode plate on the standbytable.

FIG. 14 is a flowchart illustrating a procedure for checking a positionof the electrode plate with respect to a stacked body.

FIG. 15 is a diagram illustrating captured image data for checking takenby an imaging unit for checking.

FIG. 16 is a diagram illustrating a state where a table for stacking isat a second position.

FIG. 17 is a diagram illustrating a state where the positive electrodeplate is placed on the upper part and is pressed by a second claw part.

FIG. 18 is a diagram illustrating a state where the table for stackingis moving to one side.

FIG. 19 is a diagram illustrating a state where the table for stackingis further moving to one side.

FIG. 20 is a diagram illustrating a state where the table for stackingis at a first position.

FIG. 21 is a diagram illustrating a state where the negative electrodeplate is placed on the upper part and is pressed by a first claw part.

FIG. 22 is a flowchart illustrating an operation in a learning mode.

FIG. 23 is a flowchart illustrating tension control of the separator.

FIG. 24 is a flowchart illustrating the tension control of theseparator.

FIG. 25 is a flowchart illustrating a separating process of the stackedcell.

FIG. 26 is a diagram illustrating a moved state of a separator holdingunit after cutting.

FIG. 27 is a diagram illustrating a state where the separator holdingunit has passed the separator to the table for stacking.

FIG. 28 is a diagram illustrating the table for stacking moved to thefirst position.

FIG. 29 is a flowchart illustrating a separator connecting operation.

DESCRIPTION OF EMBODIMENTS

Hereinafter an embodiment of the present invention is described withreference to the drawings.

Stacked Cell Manufacturing Device 100

FIG. 1 is a schematic layout diagram of a stacked cell manufacturingdevice 100 according to the present invention. FIG. 2 is a functionalblock diagram of the stacked cell manufacturing device 100. Note that inthe stacked cell manufacturing device 100 of this embodiment, movementdirection Tr1 of a table for stacking 21 is shown by an arrow in thestacked cell manufacturing device 100 illustrated in FIG. 1 .

In the movement direction Tr1 of the table for stacking 21, the leftside from a roller pair 131 described later is referred to as one sideOp, while the right side from the same is referred to as the other sideTp. The table for stacking 21 moves linearly in a reciprocating manner,for example, between the one side Op and the other side Tp. When thetable for stacking 21 moves between the one side Op and the other sideTp, a separator S is folded in a bellows shape. For instance, themovement direction Tr1 can also be said as a thickness direction of theseparator S fed from the roller pair 131. Here, the bellows shape is ashape of a tape-like sheet folded with a width in a certain range andstacked, and is also referred to as a zigzag folded shape.

The stacked cell manufacturing device 100 folds the tape-like separatorS fed from a separator roll Sr in a bellows shape, and dispose negativeelectrode plates 200 and positive electrode plates 300 alternately invalley fold parts of the bellows-shaped folded separator S, so as toform a stacked cell 400 (see FIG. 3 ). The stacked cell 400 is used fora stacked type battery Bp (see FIG. 3 ). In the following description,electrodes before being stacked are referred to as electrode plates Ep.

Stacked Battery Bp

Here, an example of the stacked type battery Bp is described withreference to the drawings. FIG. 3 is an exploded perspective viewillustrating an outline of the stacked type battery Bp. As illustratedin FIG. 3 , the stacked type battery Bp includes a case Cs and thestacked cell 400. The case Cs has a substantially rectangular box shape,for example, with an open upper part, which is closed by a lid Ct. Inthe stacked type battery Bp, the stacked cell 400 is housed inside thecase Cs with electrolytic solution. Further, the lid Ct closes and sealsthe opening so that the electrolytic solution does not leak.

The stacked cell 400 includes the negative electrode plates 200, thepositive electrode plates 300, and the separator S. The separator S ismade of material that has insulating properties and can transmit ions.Further, the separator S is folded in a bellows shape. The negativeelectrode plates 200 and the positive electrode plates 300 are disposedalternately in the valley fold parts of the separator S so that thestacked cell 400 is formed. Note that the stacked cell 400 illustratedin FIG. 3 has a structure in which the three negative electrode plates200 and the two positive electrode plates 300 are stacked, but an actualnumber of the stacked layers is not limited to this.

The negative electrode plate 200 is a flat plate made of conductivematerial having a rectangular shape in a plan view. The negativeelectrode plate 200 has a terminal part 201 protruding from one of apair of short sides. In addition, similarly to the negative electrodeplate 200, the positive electrode plate 300 is a flat plate made ofconductive material having a rectangular shape in a plan view. Thepositive electrode plate 300 has a terminal part 301 protruding from oneof a pair of short sides. Note that in the stacked cell 400, thenegative electrode plates 200 and the positive electrode plates 300 arestacked in such a manner that the terminal part 201 and the terminalpart 301 protrude from opposite sides to each other, for example. Notethat although not illustrated, the terminal parts 201 of the negativeelectrode plates 200 are electrically connected to each other, while theterminal parts 301 of the positive electrode plates 300 are electricallyconnected to each other. The connection of the terminal parts is notlimited to this.

As illustrated in FIG. 3 , the short side of the negative electrodeplate 200 is longer than the short side of the positive electrode plate300. Further, in a plan view, the negative electrode plate 200 isdisposed so as to cover the positive electrode plate 300. Further, bothends in the stacking direction are the negative electrode plates 200.Note that the structure illustrated in FIG. 3 is an example. It may bepossible to adopt a structure in which each end or one end in thestacking direction is the positive electrode plate 300. Further, theseparator S is disposed on the outside of the both ends. Although thenegative electrode plate 200 and the positive electrode plate 300 have arectangular shape in a plan view in the stacked type battery Bpillustrated in FIG. 3 , they may have a shape other than the rectangularshape, such as a square shape or a polygonal shape in a plan view. Notethat output power of the stacked cell 400 is determined depending on theareas and the number of stacked layers of the negative electrode plate200 and the positive electrode plate 300. In other words, the areas andthe number of stacked layers of the negative electrode plate 200 and thepositive electrode plate 300 are determined in accordance with capacityor the like required to the stacked type battery Bp.

The stacked cell manufacturing device 100 produces the stacked cells 400described above. Next, details of the stacked cell manufacturing device100 is described. As illustrated in FIGS. 1 and 2 , the stacked cellmanufacturing device 100 includes a separator feed unit 1, a foldingunit 2, an electrode feed unit 3, a stacked cell separating unit 4, anda control unit 5 (see FIG. 2 ). The stacked cell manufacturing device100 is controlled by the control unit 5.

Control Unit 5

The control unit 5 includes, for example, a processing circuit 51 and astorage circuit 52. The processing circuit 51 is a circuit thatprocesses various information, and includes an arithmetic circuit suchas a CPU, an MPU, or the like. In addition, the processing circuit 51controls drive of individual units of the stacked cell manufacturingdevice 100 based on the processing result.

The storage circuit 52 is a circuit including or connected to storagemedia such as a

ROM, a RAM or other semiconductor memory, a flash memory or other memoryhaving portability, and a hard disk or the like. It may be possible thatvarious programs such as a control program or a processing program arestored in the storage circuit 52, and that the program corresponding tothe process is read out as necessary so that the processing circuit 51can execute the program for performing the process.

Separator Feed Unit 1

As illustrated in FIG. 1 , the separator feed unit 1 feeds to thefolding unit 2 the tape-like separator S pulled out from the separatorroll Sr. The separator feed unit 1 includes a separator roll attachmentunit 11, a separator conveying unit 12, a separator roller 13, and aconnecting unit 14.

Separator Roll Attachment Unit 11

The separator roll Sr is attached to the separator roll attachment unit11 in a rotatable manner. The stacked cell manufacturing device 100illustrated in FIG. 1 includes two separator roll attachment units 11,for example. The separator rolls Sr are attached to the two separatorroll attachment units 11, respectively and independently. The separatorroll Sr can rotate so that the separator S can be pulled out from theseparator roll Sr.

Each of the separator roll attachment units 11 has a separator remainingamount detector 111 (see FIG. 2 ) that detects a remaining amount of theattached separator roll Sr. The separator roll Sr is formed by windingthe separator S. Therefore, when the separator S is pulled out, thediameter of the separator roll Sr decreases. The separator remainingamount detector 111 detects the diameter of the separator roll Sr so asto detect the remaining amount of the separator roll Sr. Note that themethod of detecting the remaining amount of the separator roll Sr is notlimited to this example.

Separator Conveying Unit 12

The separator conveying unit 12 conveys the separator S to the separatorroller 13. The separator conveying unit 12 includes a conveying roller121, a conveyance path adjustment unit 122, a traction roller 123, and atension measuring unit 124.

The conveying roller 121 is a roller disposed in a rotatable manner andits outer circumference surface contacts with the tape-like separator S.The conveying roller 121 guides conveyance of the separator S. In thestacked cell manufacturing device 100, the separator S contacts with theouter circumference surface of the conveying roller 121 and itsconveyance direction is bent. The conveying roller 121 may contact witha linearly conveyed part of the separator S so as to guide the same.Note that the stacked cell manufacturing device 100 of this embodimentis described with an example having one conveying roller 121, but it mayhave a plurality of conveying rollers 121.

The conveyance path adjustment unit 122 includes a movable roller 125that is rotatable and movable. The movable roller 125 is disposed in amanner capable of approaching or separating from the conveying roller121. The rotation axis of the movable roller 125 is parallel to therotation axis of the conveying roller 121. As the movable roller 125separates more from the conveying roller 121, a pulled-out length of theseparator S is longer, and when it moves in the opposite direction, thepulled-out length of the separator S decreases. In other words,depending on the position of the movable roller 125, a separatorconveyance route in the separator conveying unit 12, i.e., a conveyancedistance varies. According to an instruction from the control unit 5,the conveyance path adjustment unit 122 moves the movable roller 125 toapproach or separate from the conveying roller 121.

As illustrated in FIG. 1 , in the stacked cell manufacturing device 100,the separator S turns around the movable roller 125 and is sent to thetraction roller 123. The traction roller 123 is a roller disposed in arotatable manner. The traction roller 123 has a not-shown drive unit andis controlled to rotate based on an instruction from the control unit 5.

An outer circumference surface of the traction roller 123 sucks theseparator S, for example. Therefore, friction force between theseparator S and the traction roller 123 is larger than that between theseparator S and the conveying roller 121 or the conveyance pathadjustment unit 122. The traction roller 123 can change tensions of theseparator S on the upstream side and the downstream side of the tractionroller 123 in the conveyance direction, by its rotation speed. In otherwords, the traction roller 123 can apply different tensions to theseparator S on the upstream side and the downstream side.

In the stacked cell manufacturing device 100 of this embodiment, thetraction roller 123 uses one roller. Without limiting to this structure,however, it may be possible, for example, to dispose two rollers havingparallel rotation axes, so that outer circumference surfaces of themcontact each other and that the contact past (nip part) hold theseparator S.

The separator S turns around the traction roller 123 and is sent to thetension measuring unit 124. The tension measuring unit 124 measurestension of the separator S. The tension measured by the tensionmeasuring unit 124 is sent to the control unit 5. The tension measuringunit 124 can be a load cell, for example, but this is not a limitation.It is possible to widely adopt a structure capable of measuring tensionof the separator S accurately and quickly. The separator S is bent bythe tension measuring unit 124 and is sent to the separator roller 13disposed below. The separator conveying unit 12 has an edge detector 126disposed between the tension measuring unit 124 and the separator roller13. The edge detector 126 detects an edge of the separator S in thewidth direction. The edge detector 126 can detect meandering of theseparator S, a variation of the width thereof, and the like, forexample.

Separator Roller 13

The separator roller 13 feeds the separator S from the separator feedunit 1 to the folding unit 2. The separator roller 13 includes theroller pair 131. The roller pair 131 includes two rollers havingparallel rotation axes.

When the table for stacking 21 of the folding unit 2 moves in themovement direction Tr1, the roller pair 131 of the separator roller 13is moved upward not to interfere with the folding unit 2, on the basisof an instruction from the control unit 5. Details of the movement ofthe roller pair 131 in the up and down direction will be describedlater.

Connecting Unit 14

In the stacked cell manufacturing device 100, the separator S is pulledout alternately from the two separator rolls Sr attached to the twoseparator roll attachment units 11. The leading ends in the conveyancedirection of the separators S pulled out respectively from the separatorrolls Sr are held by the connecting unit 14. Further, the connectingunit 14 sends the separator S from one of the separator rolls Sr to theseparator conveying unit 12.

The connecting unit 14 is connected to the control unit 5 and operatesaccording to instructions from the control unit 5. When the remainingamount of one separator roll Sr becomes less than a certain amount, theconnecting unit 14 connects the separator S pulled out from the otherseparator roll Sr to the rear end in the conveyance direction of theseparator S from the one separator roll Sr. Note that after switchingfrom the one separator roll Sr to the other separator roll Sr to pullout the separator S, a new separator roll Sr is attached to the oneseparator roll attachment unit 11. In this way, the connecting unit 14performs the automatic connection based on the remaining amounts of thetwo separator rolls Sr, and hence stop time for replacing the separatorroll Sr can be reduced.

As to the structure of the connecting unit 14, it is possible to adoptthe same structure of a conventional and well-known device forconnecting tape-like members. Therefore, description of detailedstructure of the connecting unit 14 is omitted. In addition, operationsof the stacked cell manufacturing device 100 when the connecting unit 14connects the separators S will be described later.

The separator feed unit 1 has the structure described above. Theseparator S is fed from the separator feed unit 1 to the folding unit 2.Next, details of the folding unit 2 is described.

Folding Unit 2

FIG. 4 is an enlarged perspective view of the folding unit 2. FIG. 4illustrates the table for stacking 21 with a stacked body 500 before thestacking is completed, and illustration of the separator S is omitted.

As illustrated in FIG. 1 , the folding unit 2 folds the separator S fedfrom the separator roller 13, in a bellows shape. In the stacked cellmanufacturing device 100, the folding unit 2 is disposed horizontally toor below the roller pair 131 of the separator roller 13. The foldingunit 2 includes the table for stacking 21, a first claw part 22, and asecond claw part 23. Furthermore, it may include an imaging unit forchecking 24.

Table for Stacking 21

The table for stacking 21 has a rectangular shape in a plan view. Thetable for stacking 21 is moved in a reciprocating manner by a tablemoving unit for stacking 211 (see FIG. 2 ) controlled by the controlunit 5. In a front view, the table for stacking 21 moves in areciprocating manner, between a first position P1 on one side Op (seeFIG. 8 or the like described later) and a second position P2 on theother side Tp (see FIG. 16 or the like described later) with respect tothe roller pair 131 of the separator roller 13.

In addition, the first claw part 22 and the second claw part 23described later holds the separator S on the upper surface of the tablefor stacking 21. Furthermore, it may be possible to provide a pluralityof holes (not shown) to the upper surface of the table for stacking 21,and to suck air through the holes so that the separator S is absorbed(vacuum-absorbed). Note that similarly to the structure with holes, itmay be made of material having gaps such as mesh or porous material.With the structure described above, the table for stacking 21 holds theseparator S.

When the table for stacking 21 moves to the first position P1, theelectrode plate Ep fed from the electrode feed unit 3 is placed on theupper part of the bellows-shaped folded separator S. The electrode plateEp is used as the negative electrode plate 200 or the positive electrodeplate 300 in the stacked cell 400. When the table for stacking 21 is atthe first position P1 (see FIG. 8 ), the electrode plate Ep as thenegative electrode plate 200 is placed on the upper part of the tablefor stacking 21, while when the table for stacking 21 is at the secondposition P2 (see FIG. 16 ), the electrode plate Ep as the positiveelectrode plate 300 is placed on the same.

The electrode plate Ep is made to contain metal such as aluminum havingconductivity. In addition, the electrode plate Ep has a rectangularshape in a plan view, and has a protrusion Epm that protrudes outward inthe longitudinal direction from one short side (see FIG. 8 or the like).The protrusion Epm is a part to be the terminal part 201 of the negativeelectrode plate 200, or the terminal part 301 of the positive electrodeplate 300. Every time when the table for stacking 21 repeats thereciprocating movement, the negative electrode plate 200 and thepositive electrode plate 300 are stacked.

The table for stacking 21 can also move in the up and down direction.The table for stacking moves downward by the thickness of the electrodeplate Ep every time when the negative electrode plate 200 or thepositive electrode plate 300 is stacked. In this way, the upper surfaceof the stacked body 500 that is being stacked on the upper part of thetable for stacking 21 can be always at a constant height. In this way,the electrode plate Ep can be accurately conveyed by a second conveyingunit 332 described later.

First Claw Part 22 and Second Claw Part 23

As illustrated in FIG. 4 , the first claw part 22 and the second clawpart 23 are disposed above the table for stacking 21. The first clawpart 22 presses a corner on the other side Tp of the upper surface ofthe negative electrode plate 200 placed on the upper part of thebellows-shaped folded separator S, on the upper part of the table forstacking 21 at the first position P1. The first claw part 22 iscontrolled to move by the control unit 5, and is moved in the horizontaldirection perpendicular to the up and down direction and the movementdirection. Note that in the stacked cell manufacturing device 100, apair of the first claw parts 22 are disposed in the longitudinaldirection of the table for stacking 21, but this is not a limitation.

The second claw part 23 presses a corner on the one side Op of the uppersurface of the positive electrode plate 300 placed on the upper part ofthe bellows-shaped folded separator S, on the upper part of the tablefor stacking 21 at the second position P2. The second claw part 23 iscontrolled to move by the control unit 5, and is moved in the horizontaldirection perpendicular to the up and down direction and the movementdirection. Note that in the stacked cell manufacturing device 100, apair of the second claw parts 23 are disposed in the longitudinaldirection of the table for stacking 21, but this is not a limitation.

After the second claw part 23 presses the positive electrode plate 300,the first claw part 22 moves from the stacked body 500 in the horizontaldirection to a retreat position, which does not overlap the electrodeplate Ep placed on the table for stacking 21 in a plan view. Note thatthe retreat position of the first claw part 22 can be selected from awide area that does not interfere with the electrode plate Ep when it isplaced to be the negative electrode plate 200, but after that, it isrequired to press the negative electrode plate 200. Therefore, theretreat position of the first claw part 22 is preferably near the tablefor stacking 21, for example.

In addition, after the first claw part 22 presses the negative electrodeplate 200, the second claw part 23 moves from the stacked body 500 inthe horizontal direction to a retreat position, which does not overlapthe electrode plate Ep disposed on the table for stacking 21 in a planview. Note that the retreat position of the second claw part 23 can beselected from a wide area that does not interfere with the electrodeplate Ep when it is placed to be the positive electrode plate 300, butafter that, it is required to press the positive electrode plate 300.Therefore, the retreat position of the second claw part 23 is preferablynear the table for stacking 21, for example.

Imaging Unit for Checking 24

The imaging unit for checking 24 takes an image of the negativeelectrode plate 200 or the positive electrode plate 300 placed on thetable for stacking 21. The imaging unit for checking 24 is disposedabove each of the table for stacking 21 placed at the first position P1and the table for stacking 21 placed at the second position P2. Notethat the imaging unit above the first position P1 is referred to as animaging unit for checking 24N, while the imaging unit above the secondposition P2 is referred to as an imaging unit for checking 24P, asnecessary for discrimination (see FIG. 1 or the like).

In the stacked cell manufacturing device 100 according to thisembodiment, the separator roller 13 is fixed in the horizontaldirection, and the table for stacking 21 moves, so that the separator Sis folded in a bellows shape, and that the negative electrode plate 200and the positive electrode plate 300 are stacked. Therefore, comparedwith the conventional structure of moving the separator roller 13, theseparator roller 13 hardly interfere with imaging, and this ispreferable.

In addition, the imaging unit for checking 24N is fixed above the firstposition P1, while the imaging unit for checking 24P is fixed above thesecond position P2. Therefore, the imaging unit for checking 24N and theimaging unit for checking 24P have fixed angles of view, and thecaptured image data for checking Img (FIG. 14 described later) can betaken with a constant shape and size using the imaging unit for checking24N and the imaging unit for checking 24P. In this way, accuracy ofchecking based on the captured image data for checking Img can beenhanced.

Electrode Feed Unit 3

Next, details of the electrode feed unit 3 is described with referenceto the drawings. FIG. 5 is a schematic layout diagram of the electrodefeed unit 3. FIG. 6 is a perspective view of a notch forming unit 37.FIG. 7 is a perspective view of an electrode cutting unit 36. Asillustrated in FIG. 1 , in the stacked cell manufacturing device 100,the electrode feed unit 3 includes two electrode plate feed units 30,for example. The two electrode plate feed units 30 are disposed on theone side Op and the other side Tp, respectively, in the movementdirection Tr1. The electrode plate feed unit 30 disposed on the one sideOp feeds the electrode plate Ep that is stacked to be the negativeelectrode plate 200. The electrode plate feed unit 30 disposed on theother side Tp feeds the electrode plate Ep that is stacked to be thepositive electrode plate 300. Note that the electrode plate feed unit 30that feeds the electrode plate Ep to be the negative electrode plate 200is referred to as an electrode plate feed unit 30N, while the electrodeplate feed unit 30 that feeds the electrode plate Ep to be the positiveelectrode plate 300 is referred to as an electrode plate feed unit 30P,as necessary for discrimination.

The electrode plate feed unit 30N and the electrode plate feed unit 30Phave different conductive sheets Sh before the electrode plate Ep isformed. Specifically, the material to form the conductive sheet Sh isdifferent, and the direction and shape of a protrusion Shm are differentbetween them. Other than these points, the electrode plate feed unit 30Nand the electrode plate feed unit 30P have substantially the samestructure. Therefore, the electrode plate feed unit 30N is illustratedin FIG. 5 , and the electrode plate feed unit 30N is described asreference. In addition, FIGS. 6 and 7 also illustrate the notch formingunit 37 and the electrode cutting unit 36 disposed in the electrodeplate feed unit 30N.

FIGS. 5, 6, and 7 illustrate the electrode plate feed unit 30N or a partthereof. The conductive sheet Sh conveyed in the electrode plate feedunit 30N has protrusions Shm to be the terminal parts 201 on one side inthe width direction, for example. The protrusions Shm may be provided tothe conductive sheet Sh in advance, or may be formed in the electrodefeed unit 3. Here, it is supposed that they are provided to theconductive sheet Sh in advance.

As illustrated in FIG. 5 as an example, the electrode plate feed unit30N includes a standby table 31, a position adjusting table 32, aconveying unit 33, an imaging unit for adjustment 34, a conductive sheetconveying unit 35, the electrode cutting unit 36, the notch forming unit37, a conveyor 381, and a cleaner 382. In the electrode plate feed unit30N, the conductive sheet Sh pulled out from a conductive sheet rollShr, which is formed by winding the conductive sheet Sh in a roll shape,is cut in a predetermined length so that the electrode plate Ep is made.Then, the electrode plate Ep is fed to the table for stacking 21.

Note that a structure may be adopted in which the standby table 31 isnot provided, and the end part of the conveyor 381 on the side of theposition adjusting table 32 is also used as the standby table. Inaddition, a structure may be adopted in which the position adjustingtable 32, the notch forming unit 37, the cleaner 382, or the like is notprovided.

In addition, in the structure without the position adjusting table 32,it may be possible to adjust the position of the electrode plate Ep onthe way of transferring from the standby table 31 (including thestructure in which the end part of the conveyor 381 is used as the same)to the table for stacking 21, and to place the electrode plate Ep afterthe adjustment on the table for stacking 21.

Conductive Sheet Conveying Unit 35

The conductive sheet conveying unit 35 includes a conductive sheet rollattachment unit 351. Note that FIG. 5 illustrates an example of tworolls, but a single roll may be possible. The electrode plate feed unit30N includes two conductive sheet roll attachment units 351, to whichthe conductive sheet rolls Shr are attached respectively. In theconductive sheet conveying unit 35, the conductive sheet Sh is pulledout from one of the conductive sheet rolls Shr, which is attached to oneof the conductive sheet roll attachment units 351, and is conveyed.Further, when a remaining amount of one conductive sheet roll Shrbecomes a certain amount or less, the conductive sheet Sh isautomatically pulled out from the other conductive sheet roll Shrattached to the other conductive sheet roll attachment unit 351. In thisway, it is not necessary to stop the electrode plate feed unit 30N forattaching the conductive sheet roll Shr, and the time necessary formanufacturing the stacked cell 400 can be reduced.

The conductive sheet conveying unit 35 includes a plurality of rollersfor conveying the conductive sheet Sh pulled out from the conductivesheet roll Shr. The conductive sheet Sh conveyed by the conductive sheetconveying unit 35 is cut by the electrode cutting unit 36, and theelectrode plate Ep is formed. The electrode cutting unit 36 cuts theconductive sheet Sh with reference to notches Nt formed on both sides ofthe conductive sheet Sh in the width direction. Therefore, in theconductive sheet conveying unit 35, the notch forming unit 37 isdisposed on the upstream side of the electrode cutting unit 36.

Notch Forming Unit 37

The notch forming unit 37 forms the notches Nt on both sides in thewidth direction of the conveyed conductive sheet Sh. The notch formingunit 37 can have a structure for cutting foil by a normal cuttingmethod, for example, a structure illustrated in FIG. 5 as an example,which includes a notching mold 371, an edge detector 372, and a moldmoving unit 373 (see FIG. 2 ). In addition, other structure may beadopted, and it is possible to widely adopt a structure using a lasercutting method or the like, for example.

As illustrated in FIG. 6 , the notching mold 371 includes a die 374 anda punch 375. The die 374 has a recess with which the punch 375 engages.In the state where the side of the conductive sheet Sh as a work isplaced on the die 374, the punch 375 is pressed into the recess, and thenotch is formed. The die 374 has two recesses arranged in the widthdirection of the conductive sheet Sh. Further, a pair of the punches 375are arranged in the width direction to be capable of engaging with therecesses, respectively.

The notching mold 371 can move in the width direction of the conveyedconductive sheet Sh. In other words, the notching mold 371 can bepositioned with respect to the side of the conductive sheet Sh. Thenotching mold 371 includes the common die 374 and the two punches 375,which move as a unit in the width direction of the conductive sheet Sh.Without limiting to this structure, however, it may be possible thatthere are separate dies 374 in the width direction, which moveindependently.

The edge detector 372 is disposed on the upstream side of the notchingmold 371 in the conveyance direction of the conductive sheet Sh. Theedge detector 372 detects the side end (edge) of the conductive sheetSh. Then, it sends edge information to the control unit 5. Note that theedge detector 372 can have a structure for taking an image, but withoutlimiting to this, it is possible to widely adopt a method of accuratelydetecting the edge of the conductive sheet Sh.

The mold moving unit 373 is connected to the control unit 5 and can movethe notching mold 371 in the width direction of the conductive sheet Sh.On the basis of the edge information on the upstream side in theconveyance direction of the conductive sheet Sh sent from the edgedetector 372, the control unit 5 moves the notching mold 371 so that thenotch Nt is formed at a preset position of the conductive sheet Sh.

As the notch forming unit 37 is configured as described above, even ifthe conductive sheet Sh conveyed by the conductive sheet conveying unit35 is meandering, appropriate notches can be formed at the edges of theconductive sheet Sh.

The edge detector 372 has the structure to detect the edge on one sidein the width direction of the conductive sheet Sh, but without limitingto this, it may be possible to detect both edges. If the edge detector372 has a structure to detect both edges of the conductive sheet Sh, itis preferred to move the notching molds 371 independently on both edgesin the width direction. In this way, even if the width of the conductivesheet Sh varies, appropriate notches can be formed at the edges of theconductive sheet Sh.

After the notches are formed at the edges by the notch forming unit 37,the conductive sheet Sh is sent to the electrode cutting unit 36.

Electrode Cutting Unit 36

As illustrated in FIG. 7 , the electrode cutting unit 36 includes afixed blade 361, a rotary blade 362, a rotary blade moving unit 363 (seeFIG. 2 ), a first conveying roller unit 364, and a second conveyingroller unit 365.

The conductive sheet Sh to be conveyed to the electrode cutting unit 36is conveyed by the first conveying roller unit 364 and the secondconveying roller unit 365. As illustrated in FIG. 7 as an example, thefirst conveying roller unit 364 includes a lower roller 3641 disposedunder the conductive sheet Sh to have an axial length more than thewidth of the conductive sheet Sh, and upper rollers 3642 disposed abovethe lower roller 3641 so that three of them are arranged in the widthdirection of the conductive sheet Sh.

The first conveying roller unit 364 holds the conductive sheet Shbetween the lower roller 3641 and the upper rollers 3642. Further, thefirst conveying roller unit 364 is connected to the control unit 5 andis rotated by a not-shown drive unit. Note that the first conveyingroller unit 364 has three upper rollers 3642, but this is not alimitation. It is possible to widely adopt a structure capable ofsecurely holding the conductive sheet Sh.

The second conveying roller unit 365 includes a lower roller 3651disposed under the conductive sheet Sh to have an axial length more thanthe width of the conductive sheet Sh, an upper rollers 3652 disposedabove the lower roller 3651 so that three of them are arranged in thewidth direction of the conductive sheet Sh.

The second conveying roller unit 365 holds the conductive sheet Shbetween the lower roller 3651 and the upper rollers 3652. Further, thesecond conveying roller unit 365 is connected to the control unit 5 andis rotated by a not-shown drive unit.

In addition, three conveying roller units 366, 367, and 368 are disposedon the downstream side of the second conveying roller unit 365 (see FIG.5 ). Each of the conveying roller units 366, 367, and 368 has the samestructure as the second conveying roller unit 365.

In the stacked cell manufacturing device 100 of this embodiment, theelectrode plate feed unit 30 (30N, 30P) cuts the conductive sheet Sh tomake the electrode plates Ep and feed them to the stacked body 500. Anoperator handles the conductive sheet roll Shr that is easier to conveyor attach than the electrode plates Ep, and hence workability is high.

Fixed Blade 361, Rotary Blade 362, and Rotary Blade Moving Unit 363

The fixed blade 361 and the rotary blade 362 are disposed between thefirst conveying roller unit 364 and the second conveying roller unit365. The fixed blade 361 is disposed between the lower roller 3641 andthe lower roller 3651. The fixed blade 361 is made of high hardnessmaterial such as tool steel or cemented carbide alloy. In the electrodecutting unit 36, the fixed blade 361 has a rectangular solid shape, andone of edge lines thereof forms a fixed cutting blade 3611. Theconductive sheet Sh is conveyed over the fixed cutting blade 3611.

The rotary blade 362 is made of high hardness material similarly to thefixed blade 361. The material of the rotary blade 362 may be the same asor different from that of the fixed blade 361. The rotary blade 362 hasa disk shape, and the outer edge thereof forms a rotary cutting blade3621.

The rotary blade moving unit 363 can rotate and move the rotary blade362 along the fixed blade 361. In the state where the rotary cuttingblade 3621 contacts with the fixed cutting blade 3611, the rotary blademoving unit 363 moves the rotary blade 362 along the fixed blade 361while rotating the same, so that the conveyed conductive sheet Sh can becut. Note that it may be possible to provide a biasing member such as aspring to bias the rotary blade 362 toward the fixed blade 361 so thatthe fixed cutting blade 3611 and the rotary cutting blade 3621 contacteach other securely.

The rotary blade moving unit 363 operates according to instructions fromthe control unit 5. In the electrode cutting unit 36, a not-showndetector detects the notch formed at the edge of the conductive sheetSh. Further, when the detector detects the notch, the control unit 5sends an instruction to the rotary blade moving unit 363 to drive andmove the rotary blade 362, so as to cut the conductive sheet Sh in sucha manner that the notches are connected to each other. When theconductive sheet Sh is cut in the electrode cutting unit 36, theelectrode plate Ep is formed.

As the rotary blade 362 has a disk shape, a simple structure can berealized, and accuracy of the shape of the rotary cutting blade 3621 canbe enhanced easily. In addition, with the structure in which the rotarycutting blade 3621 of the rotary blade 362 rotates while contacting withthe fixed cutting blade 3611 of the fixed blade 361, even if accuracy ofcombination of the fixed cutting blade 3611 and the rotary cutting blade3621 is varied a little, accuracy of cutting can be enhanced.

In addition, if wearing of the “blades” can be a problem, a structuremay be adopted in which a tiny gap is formed between the rotary cuttingblade 3621 of the rotary blade 362 and the fixed cutting blade 3611 ofthe fixed blade 361, as a non-contact state (hereinafter also referredto as a proximity or proximate state), for performing the cutting. Notethat by changing the rotation speed of the rotary blade 362 with respectto the feed amount of the rotary blade 362 toward the fixed blade 361,sharpness of cutting can be changed. Therefore, this is suitable in thecase where wearing of the “blades” can be a problem.

For instance, the conductive sheet Sh includes a part of metal foil(here, aluminum foil) only, a part of aluminum foil with an insulationlayer (e.g. ceramics such as aluminum oxide) coated, a part of aluminumfoil with active material coated. When the conductive sheet Sh is cut,exfoliation between the aluminum foil and the active material tends tooccur at the cutting end. Therefore, in the electrode cutting unit 36,the rotational frequency of the rotary blade 362 is adjusted dependingon a cutting position of the conductive sheet Sh. For instance, whencutting the end part, the rotational frequency is decreased. In thisway, occurrence of exfoliation between the aluminum foil and the activematerial can be suppressed.

In addition, in the electrode cutting unit 36, the fixed blade 361 is alinear blade, and the rotary blade 362 rotates and moves from one end tothe other end of the fixed blade 361 (forward), so as to cut theconductive sheet Sh, and after that the rotary blade 362 may rotate andmove to return from the other end to the one end of the fixed blade 361(backward), at this time, the conductive sheet Sh may be cut.

If the rotary blade 362 rotates and moves forward and backward, the samepart of the rotary cutting blade 3621 of the rotary blade 362 alwayscontacts or comes close to the fixed cutting blade 3611 of the fixedblade 361. Further, the conductive sheet Sh is sent to the same orsubstantially the same position of the fixed blade 361. Therefore, theconductive sheet Sh is cut by the same part of the rotary cutting blade3621.

In the electrode cutting unit 36 having this structure, the control unit5 may control the rotary blade moving unit 363 to idle the rotary blade362 when the rotary blade 362 is at least one of the one end and theother end of the fixed blade 361, for example. With this control, it ispossible to control different parts of the rotary cutting blade 3621 ofthe rotary blade 362 to contact or come close to the fixed cutting blade3611 of the fixed blade 361, every time when cutting the conductivesheet Sh.

By performing the control described above, it is possible to cut theconductive sheet Sh by different parts of the rotary cutting blade 3621of the rotary blade 362 every time. As a result, when cutting theconductive sheet Sh, it is possible to use different parts that contactsor comes close to the insulation layer for cutting, and it is possibleto prevent that a part of the rotary cutting blade 3621 is wornintensively. In addition, it is possible to use different parts thatcontacts or comes close to the aluminum foil for cutting, and it ispossible to prevent aluminum adhesion. In this way, deterioration of therotary blade 362 can be prevented, and hence long life of the rotaryblade 362 can be achieved.

Note that the rotation angle of the rotary blade 362 when it is idled isan angle other than multiples of 360 degrees. In this way, the part ofthe rotary cutting blade 3621 of the rotary blade 362 that contacts orcomes close to the fixed cutting blade 3611 of the fixed blade 361 isvaried, and the effect of preventing the intensive wearing or theadhesion can be enhanced, so that longer life of the rotary blade 362can be achieved. In addition, the idling of the rotary blade 362 may beperformed every time when cutting the conductive sheet Sh, or every timewhen the cutting is performed a plurality of times. Furthermore, therotation angle of the rotary blade 362 when it is idled may be changedevery time when the cutting is performed a predetermined times.

The electrode cutting unit 36 cuts the conductive sheet Sh in the statewhere the conductive sheet Sh is stopped. Here, if tension of theconductive sheet Sh is high, the conductive sheet Sh may be ripped atthe point where rotary blade 362 contacts as soon as it contacts. Inaddition, even if the tension is not so high to cause ripping, if thetension is a certain level or higher, the tension when the cutting isperformed tends to cause an unstable shape of the electrode plate Ep.

Therefore, when the electrode cutting unit 36 stops conveyance of theconductive sheet

Sh, the control unit 5 stops the second conveying roller unit 365 afterstopping the first conveying roller unit 364. In this way, appropriatetension can be applied to the part of the conductive sheet Sh betweenthe first conveying roller unit 364 and the second conveying roller unit365, and hence the shape can be stabled. Further, it is possible toprevent “bend” of the conductive sheet Sh that can be generated when theconductive sheet Sh is pushed and conveyed by the first conveying rollerunit 364.

In addition, it may be possible that the control unit 5 stops the firstconveying roller unit 364 and the second conveying roller unit 365 atthe same time, and then rotate the second conveying roller unit 365 inthe opposite direction to the conveyance direction. In this way, tensionof the part of the conductive sheet Sh between the first conveyingroller unit 364 and the second conveying roller unit 365 can beappropriately relaxed.

In other words, as the first conveying roller unit 364 and the secondconveying roller unit 365 are controlled by the control unit 5 in thisway, tension of the part of the conductive sheet Sh between the firstconveying roller unit 364 and the second conveying roller unit 365 canbe appropriately adjusted. As described above, it is possible to reduceoccurrence of a malfunction such as unstable shape of the electrodeplate Ep after cutting or ripping of the conductive sheet Sh.

When the conductive sheet Sh is cut by the fixed blade 361 and therotary blade 362 in the electrode cutting unit 36, the electrode plateEp is formed. In the electrode cutting unit 36, it is conveyed by thee.g. three conveying roller units 366, 367, and 368 on the downstreamside of the second conveying roller unit 365. Further, the conveyor 381is disposed on the downstream side of the electrode cutting unit 36 inthe conveyance direction of the conductive sheet Sh. The electrode plateEp is fed to the upper part of the standby table 31 by the conveyor 381.

The conveyor 381 moves at a certain speed (including a certainintermittent conveyance, and certain speed conveyances with a certainintermittent conveyance therebetween). Further, the control unit 5controls rotations of the second conveying roller unit 365, and theconveying roller units 366, 367, and 368, so as to send the electrodeplate Ep to the conveyor 381 at the same speed as the moving speed ofthe conveyor 381.

The conveyor 381 faces the cleaner 382. The electrode plate Ep conveyedby the conveyor 381 is cleaned by the cleaner 382. Note that the cleaner382 can have a structure for blowing air or gas to blow off foreignobjects, dirt, or the like, for example, but this is not a limitation.It is possible to widely adopt a structure that can clean the electrodeplate Ep. The electrode plate Ep cleaned by the cleaner 382 is placed onthe standby table 31. Note that a structure without the cleaner 382 mayalso be adopted.

Standby Table 31

FIG. 8 is a perspective view illustrating a layout of the standby table31 and the position adjusting table 32. As illustrated in FIG. 8 , theelectrode plates Ep can be placed on the upper surface of the standbytable 31. The electrode plate Ep placed on the standby table 31 is heldby a first conveying unit 331 of the conveying unit 33 and is sent tothe position adjusting table 32. The standby table 31 may be movable inthe up and down direction so that the upper surface of the stackedelectrode plates Ep is always at a constant position, in accordance withthe number of the electrode plate Ep stacked on the upper surface. Forinstance, it moves downward by a distance corresponding to the thicknessof the electrode plate Ep when the electrode plate Ep is fed from theconveyor 381, while it moves upward by a distance corresponding to thethickness of the electrode plate Ep when the electrode plate Ep isconveyed by the first conveying unit 331. Note that the movement of thestandby table 31 in the up and down direction described above is anexample, and this is not a limitation.

In addition, a structure may be adopted in which the end part of theconveyor 381 on the side of the position adjusting table 32 is also usedas a substitute of the standby table, without providing the standbytable 31. In this case, the electrode plate Ep on the end part of theconveyor 381 on the side of the position adjusting table 32 is held bythe second conveying unit 332 of the conveying unit 33 and sent to theposition adjusting table 32.

Position Adjusting Table 32 and Imaging Unit for Adjustment 34

The electrode plate Ep is sent from the conveyor 381 to the standbytable 31. Therefore, a position of electrode plate Ep placed on thestandby table 31 often varies with respect to the standby table 31.Therefore, in the electrode plate feed unit 30N, the electrode plate Epis temporarily placed on the position adjusting table 32, and afterposition adjustment is performed on the position adjusting table 32, itis sent to the table for stacking 21. However, the position adjustmentis not limited to being performed on the position adjusting table 32 butmay be performed by other means or method.

As a structure without the position adjusting table 32, for example, thefollowing structure can be considered. Specifically, it includes thestandby table 31 (including the structure in which the end part of theconveyor 381 is used as the same, the same is true in the followingdescription), the imaging unit for adjustment 34 that takes an image ofthe electrode plate Ep placed on the standby table 31. Further, whentransferring the electrode plate Ep from the standby table 31 to thetable for stacking 21, the control unit 5 adjusts the position of theelectrode plate Ep so that the electrode plate Ep is fed to the normalposition with respect to the separator S, on the basis of the capturedimage data of the electrode plate Ep placed on the standby table 31 fromthe imaging unit for adjustment 34, and after the adjustment, theelectrode plate Ep is placed on the table for stacking 21.

In addition, the structure described above may further includes theimaging unit for checking 24 to take an image of the electrode plate Epplaced on the table for stacking 21, and based on the captured imagedata of the electrode plate Ep placed on the table for stacking 21 fromthe imaging unit for checking 24, the control unit 5 may further performadjustment (fine adjustment) of the position of the electrode plate Ep.With the structure described above, adjustment process of the positionof the electrode plate Ep can be performed at a higher speed.

The position adjusting table 32 itself can move in the x direction alongthe conveyance direction of the separator S, in the y direction that isthe width direction of the separator S, and in the θ direction that isthe circumferential direction of a circle around the normal of theseparator S. Further, when the position adjusting table 32 moves, theposition of the electrode plate Ep placed on the position adjustingtable 32 is adjusted. If the electrode plate Ep is shifted when theposition adjusting table 32 moves, the position adjustment can hardly beperformed. Therefore, the position adjusting table 32 may have aretention mechanism to retain the electrode plate Ep.

The retention mechanism can have a structure of sucking air to performabsorption (vacuum-absorption), for example, but this is not alimitation. In the position adjusting table 32, the position of theelectrode plate Ep is adjusted. Therefore, it is controlled so that theelectrode plates Ep are placed one by one on the position adjustingtable 32.

The position adjustment of the electrode plate Ep is performed for thesecond conveying unit 332 that conveys the electrode plate Ep from theposition adjusting table 32 to the table for stacking 21 at the firstposition P1. When the position adjustment of the electrode plate Ep isperformed, it is performed based on the captured image data taken by theimaging unit for adjustment 34 disposed above the position adjustingtable 32. The imaging unit for adjustment 34 takes an image of theelectrode plate Ep placed on the position adjusting table 32, and sendsthe captured image data to the control unit 5. In order to facilitatethe position adjustment, the imaging unit for adjustment 34 ispreferably disposed at a position that enables to take an image in thenormal direction from above the electrode plate Ep in the normaldirection.

The captured image data taken by the imaging unit for adjustment 34 issent to the control unit 5, and image processing thereof is performed bythe processing circuit 51 of the control unit 5. Then, the processingcircuit 51 calculates a movement amount of the position adjusting table32, based on a position deviation between the appropriate position ofthe electrode plate Ep and the position of the electrode plate Ep in thecaptured image data. On the basis of the calculated movement amount, thecontrol unit 5 moves the position adjusting table 32 so as to performthe position adjustment of the electrode plate Ep. Details of theposition adjustment of the electrode plate Ep will be described later.

Conveying Unit 33

The conveying unit 33 conveys the electrode plate Ep to the table forstacking 21 at the first position P1. The conveying unit 33 includes thefirst conveying unit 331, the second conveying unit 332, and aconnecting arm 333. The first conveying unit 331 conveys the electrodeplate Ep, which has been conveyed and accumulated on the standby table31, to the position adjusting table 32. The second conveying unit 332conveys the electrode plate Ep after the position adjustment on theposition adjusting table 32 to the upper part of the table for stacking21 at the first position P1.

The first conveying unit 331 and the second conveying unit 332 have thesame structure. The first conveying unit 331 and the second conveyingunit 332 have the lower surface that can contact and hold the electrodeplate Ep. The first conveying unit 331 and the second conveying unit 332can have a structure, for example, including an absorption unit on thelower surface so as to hold the electrode plate Ep by absorption (vacuumabsorption), but this is not a limitation.

Stacked Cell Separating Unit 4

FIG. 9 is a layout diagram of the stacked cell separating unit 4. Thestacked cell separating unit 4 separates the stacked cell 400 after thestacking is completed on the table for stacking 21 from the tape-likeseparator S fed from the separator feed unit 1. The separated stackedcell 400 is taken out.

As illustrated in FIGS. 1, 3, and 9 , the stacked cell separating unit 4includes a separator holding unit 41, a separator cutting unit 42, and astacked cell output unit 43 (see FIG. 1 ). The separator holding unit 41can move between a standby position Es on the one side Op and a holdingposition Cc on the other side Tp, along an arc trajectory SS passingbelow the separator roller 13. Note that the separator holding unit 41can be one that moves along a not-shown arc-shaped guide, for example,but this is not a limitation.

The trajectory SS of the separator holding unit 41 is not limited to thearc shape but may be a moving path having an elliptical arc shape, ahyperbolic shape, a linear shape, or the like, as long as the movementdoes not cause tension more than the normal value for the held separatorS. As described above, the separator S is cut in the state held by theseparator holding unit 41, and hence the end of the separator S aftercutting can be a standby state at the standby position Es by theseparator holding unit 41.

As exemplified in FIG. 9 , the standby position Es is a position wherethe separator holding unit 41 does not interfere with stacking of thestacked body 500. Specifically, it is a position where the separatorholding unit 41 does not interfere with the up and down movement of theroller pair 131, and it is a position outside the imaging angle of viewof the imaging unit for checking 24.

Further, when the separator holding unit 41 is moved to the holdingposition Cc, it holds the lower surface of the separator S connecting tothe stacked cell 400 on the table for stacking 21 at the second positionP2. The separator holding unit 41 has a structure capable of absorbing(vacuum absorbing) the separator S with the surface contacting theseparator S. Note that the holding method of the separator S by theseparator holding unit 41 is not limited to the absorption (vacuumabsorption), but it is possible to widely adopt a holding method thatcan hold the separator S without deforming or breaking the same.

The separator cutting unit 42 is disposed on the other side Tp. Theseparator cutting unit 42 can cut a part of the separator S between thepart held by the separator holding unit 41 and the stacked cell 400 onthe table for stacking 21 at the second position P2. Note that as theseparator cutting unit 42, it is possible to widely adopt a cutting toolcapable of separating the separator S in the conveyance direction.

The stacked cell separating unit 4 drives the separator holding unit 41and the separator cutting unit 42. The stacked cell separating unit 4operates according to instructions from the control unit 5. Only whenthe separator holding unit 41 holds the separator S after the stackingof the stacked cell 400 is completed, the stacked cell separating unit 4operates the separator cutting unit 42 to cut the separator S.

The stacked cell output unit 43 is disposed on the other side Tp. Afterthe separator cutting unit 42 cuts the separator S, the stacked cell 400is taken out from the table for stacking 21 at the second position P2.The stacked cell output unit 43 takes out the stacked cell 400 in thewidth direction of the separator S, i.e. in the y direction. The stackedcell output unit 43 has a shape for holding the stacked cell 400 by thesides without protrusion of the terminal part 201 or 301(see FIG. 1 ).However, without limiting to this, it may have a glove-like shape tograb the stacked cell 400 from above, for example.

The stacked cell manufacturing device 100 according to this embodimenthas the structure described above. Next, operations of the stacked cellmanufacturing device 100 is described with reference to the drawings.

Position Adjustment of Electrode Plate Ep

First, the conveying operation to convey the electrode plate Epaccumulated on the standby table 31 to the table for stacking 21 at thefirst position P1 is described with reference to the drawings. FIG. 10is a flowchart illustrating a position adjusting operation of theelectrode plate Ep. FIG. 11 is a perspective view illustrating a statewhere the first conveying unit 331 holds the electrode plate Ep on thestandby table 31. FIG. 12 is a perspective view just after placing theelectrode plate Ep on the upper surface of the position adjusting table32. FIG. 13 is a perspective view illustrating a state where the firstconveying unit 331 is moving to fetch the electrode plate on the standbytable 31.

As illustrated in FIG. 11 , the first conveying unit 331 absorbs theelectrode plate Ep accumulated on the standby table 31. In FIG. 11 , thesecond conveying unit 332 absorbs the electrode plate Ep placed on theupper part of the position adjusting table 32, and this will bedescribed later.

As illustrated in FIG. 8 , the conveying unit 33 places the electrodeplate Ep held by the first conveying unit 331 on the upper surface ofthe position adjusting table 32. Just after the electrode plate Ep isplaced on the position adjusting table 32, the imaging unit foradjustment 34 takes an image of the electrode plate Ep placed on theposition adjusting table 32, and the control unit obtains first capturedimage data (FIG. 10 , Step S101).

During the period while the first conveying unit 331 moves to thestandby table 31, the control unit 5 performs image processing andcalculates the position deviation from the appropriate position of theelectrode plate Ep, based on the position of the electrode plate Ep inthe first captured image data, the edge information of the separator Sfrom the edge detector 126, and the like. Further, on the basis of thecalculation result, the control unit 5 performs a first positionadjustment process to move the position adjusting table 32 (Step S102).As illustrated in FIG. 12 , in the first position adjustment process,the position adjusting table 32 is moved in the rotation direction (θdirection). In the case of an elongated electrode plate Ep as theelectrode plate Ep in this embodiment, if a position deviation occurs inthe rotation direction, a position deviation of the end in thelongitudinal direction increases. Therefore, in the first positionadjustment process that is the adjustment in the first time, theposition deviation in the θ direction is adjusted.

Further, after the first position adjustment is finished until thesecond conveying unit 332 holds the electrode plate Ep on the positionadjusting table 32 (see FIG. 13 ), the imaging unit for adjustment 34takes an image of the electrode plate Ep placed on the upper part of theposition adjusting table 32. The control unit 5 obtains second capturedimage data from the imaging unit for adjustment 34 (Step S103). Duringthe period while the second conveying unit 332 moves to the positionadjusting table 32, the control unit 5 performs the image processing andcalculates the position deviation from the appropriate position of theelectrode plate Ep, based on the position of the electrode plate Ep inthe second captured image data, the edge information of the separator Sfrom the edge detector 126, and the like. Further, on the basis of thecalculation result, the control unit 5 performs a second positionadjustment process to move the position adjusting table 32 (Step S104).

As illustrated in FIG. 13 , in the second position adjustment process,the position adjusting table 32 is moved in the lateral direction (xdirection) and the longitudinal direction (y direction) of the electrodeplate Ep. As described above, the position adjusting table 32 is movedin the θ direction in the first position adjustment process, and ismoved in the x direction and the y direction in the second positionadjustment process, but this is not a limitation.

When the first position adjustment process and the second positionadjustment process are performed, the electrode plate Ep placed on theupper part of the position adjusting table 32 is positioned at anappropriate position for being placed on the table for stacking 21.Further, as illustrated in FIG. 11 , the electrode plate Ep after theposition adjustment in the θ direction, the x direction, and the ydirection on the position adjusting table 32 is absorbed by the secondconveying unit 332. When the second conveying unit 332 absorbs theelectrode plate Ep, the imaging unit for adjustment 34 takes an image ofthe position adjusting table 32 with the electrode plate Ep. The controlunit 5 obtains captured image data for final adjustment from the imagingunit for adjustment 34 (Step S105).

The control unit 5 checks a final position of the electrode plate Epfrom the captured image data for final adjustment (Step S105). Note thatthe final position is the position of the electrode plate Ep held by thesecond conveying unit 332, and position adjustment on the positionadjusting table 32 cannot be performed. Therefore, the control unit 5checks whether or not the final position is an appropriate position(Step S106).

If the final position is an appropriate position (Yes in Step S106), asillustrated in FIG. 8, the control unit 5 operates the conveying unit 33to convey the electrode plate Ep held by the second conveying unit 332to the upper part of the stacked body 500, which is being stacked on theupper part of the table for stacking 21 at the first position P1 (StepS107). If the final position is not an appropriate position (No in StepS106), the control unit 5 discards the electrode plate Ep held by thesecond conveying unit 332 (Step S108). The electrode plate Ep may bediscarded by being dropped between the position adjusting table 32 andthe table for stacking 21 at the first position P1, for example, or anadditional mechanism for discarding may be provided.

Note that this embodiment describes the case where a position deviationof the electrode plate Ep occurs, but this is not a limitation. Forinstance, the electrode plate Ep may be discarded also in a case where avariation in the shape or the size of the electrode plate Ep occurs. Inthis way, a performance variation in the manufactured stacked cells 400can be suppressed. In other words, a decrease in yield of the stackedcell 400 can be suppressed.

Check of Stacking State of Stacked Body 500

Even if the position of the electrode plate Ep is adjusted as describedabove, a position deviation may occur when the second conveying unit 332places the electrode plate Ep on the upper part of the stacked body 500.Therefore, in the stacked cell manufacturing device 100, the position ofthe electrode plate Ep placed on the upper part of the stacked body 500that is currently being stacked with respect to the stacked body 500 maybe checked by providing the imaging unit for checking 24 (24N).Hereinafter, the procedure for checking the position of the electrodeplate Ep is described with reference to the drawings. FIG. 14 is aflowchart illustrating the procedure for checking the position of theelectrode plate Ep with respect to the stacked body 500. FIG. 15 is adiagram illustrating the captured image data for checking Img taken bythe imaging unit for checking 24N.

As illustrated in FIG. 8 , the electrode plate Ep held by the secondconveying unit 332 is placed on the upper part of the stacked body 500placed on the upper part of the table for stacking 21 at the firstposition P1. At this time, the imaging unit for checking 24N takes animage of the upper part of the stacked body 500. The control unit 5obtains the captured image data for checking Img from the imaging unitfor checking 24N (Step S201). Then the control unit 5 performs imageprocessing on the captured image data for checking Img so as to obtainpositions of four corners Ag of the electrode plate Ep placed on theuppermost part (Step S202).

In the folding unit 2, when the electrode plate Ep is placed, the firstclaw part 22 promptly presses the upper part of the electrode plate Ep.Therefore, as illustrated in FIG. 15 , when the imaging unit forchecking 24N takes an image of the electrode plate Ep, the corners Ag ofthe electrode plate Ep on the other side Tp cannot be directly seen.Therefore, the control unit 5 checks positions of the detection parts Cp(four parts) near the first claw parts 22 on the short sides and thelong side of the electrode plate Ep, in the captured image data forchecking Img, and from these data, the control unit 5 calculates andobtains the position of the corner Ag.

In addition, the electrode plate Ep is placed on the upper part of thesecond claw part 23. Therefore, the electrode plate Ep is inclined, andhence recognized positions of the corners Ag of the electrode plate Epon the one side Op may be not accurate positions. Therefore, normalcorner positions are calculated, based on product dimension data in thexy direction obtained on the position adjusting table 32 and the data ofthe two corners Ag on the other side Tp obtained by the detection of thedetection parts Cp.

The control unit 5 checks whether or not the four corners Ag of theelectrode plate Ep are at appropriate positions (Step S203). If at leastone of the corners Ag is not at the appropriate position (No in StepS203), the stacked body 500 that is currently being stacked is discarded(Step S205).

If the four corners Ag of the electrode plate Ep are at the appropriatepositions (Yes in Step S203), information of the four corners is storedin the storage circuit 52 (Step S204). After that, the control unit 5checks whether or not the stacked cell 400 is completed (Step S206). Ifthe stacked cell 400 is not completed (No in Step S206), the controlunit 5 continues the stacking (Step S207). Note that, after continuingthe stacking, the process returns to Step S201 so as to continue thechecking of the stacking state. In addition, if the stacked cell 400 iscompleted (Yes in Step S206), the control unit 5 operates the stackedcell output unit 43 to take out the stacked cell 400 (Step S208).

As described above, the electrode plate Ep is used as the negativeelectrode plate 200 or the positive electrode plate 300 in the stackedbody 500. The stacked cell 400 has rules such as that the positiveelectrode plate 300 is disposed inside the negative electrode plate 200in a plan view. Therefore, if a part of the corners Ag of the electrodeplate Ep to be the positive electrode plate 300 is outside the corner Agof the negative electrode plate 200, it is determined that it is not atthe appropriate position. In addition, if the corner Ag of the electrodeplate Ep to be the negative electrode plate 200 is outside thepredetermined position, the electrode plate Ep may be bent when theseparator S is folded in a bellows shape. Therefore, as described above,it is checked whether or not the position of the electrode plate Ep isthe appropriate position every time when the electrode plate Ep isdisposed, and hence a performance variation in the manufactured stackedcells 400 can be suppressed.

Stacking Operation by Folding Unit 2 and Electrode Feed Unit 3

In the stacked cell manufacturing device 100, the folding unit 2 foldsthe separator S in a bellows shape, while the negative electrode plates200 and the positive electrode plates 300 are disposed in the valleyfold parts, so that the stacked cell 400 is manufactured. Here,operations of the folding unit 2 is described with reference to thedrawings. FIG. 16 is a diagram illustrating a state where the table forstacking 21 is at the second position P2. FIG. 17 is a diagramillustrating a state where the positive electrode plate 300 is placed onthe upper part and is pressed by the second claw part 23. FIG. 18 is adiagram illustrating a state where the table for stacking 21 is movingto the one side Op. FIG. 19 is a diagram illustrating a state where thetable for stacking 21 is further moving to the one side Op. FIG. 20 is adiagram illustrating a state where the table for stacking 21 is at thefirst position P1. FIG. 21 is a diagram illustrating a state where thenegative electrode plate 200 is placed on the upper part and is pressedby the first claw part 22.

As illustrated in FIG. 16 , when the table for stacking 21 is at thesecond position P2, the negative electrode plate 200 is pressed by thefirst claw part 22. Further, the separator S is bent and folded at thefirst claw part 22. The roller pair 131 is disposed near the table forstacking 21 in the up and down direction. Therefore, it is possible toreduce the inclination angle of the separator S bent and folded at thefirst claw part 22. Note that depending on a position of the roller pair131, the bent and folded separator S can be horizontal or substantiallyhorizontal. In this way, the electrode plate Ep to the positiveelectrode plate 300 can be easily and accurately placed on the upperpart of the bent and folded separator S (see FIG. 17 ).

In addition, as the roller pair 131 is disposed near the table forstacking 21 in the up and down direction, the bent and folded separatorS can be horizontal or substantially horizontal. Therefore, thereciprocating movement of the table for stacking 21 can be short, andcycle time for manufacturing the stacked cell 400 can be reduced.

Further, after the electrode plate Ep is placed as the positiveelectrode plate 300 on the upper part, it is pressed by the second clawpart 23, and the first claw part 22 is moved in the y direction and thez direction (the direction perpendicular to the x direction and the ydirection). In this way, the first claw part 22 is pulled out frombetween the negative electrode plate 200 and the separator S (see FIG.17 ).

When the positive electrode plate 300 is placed, the height of thestacked body 500 in the stacking direction is increased. In order thatthe conveying unit 33 of the electrode feed unit 3 can accurately conveythe electrode plate Ep to the stacked body 500, the table for stacking21 moves downward by a distance corresponding to the thickness of thepositive electrode plate 300 (see FIG. 18 )

Further, the control unit 5 controls the separator roller 13 to move theroller pair 131 upward. In this way, the roller pair 131 moves to aposition that does not interfere with the table for stacking 21, thefirst claw part 22, or the second claw part 23. In this state, the tablefor stacking 21 moves to the one side Op (see FIG. 18 ). The table forstacking 21 can pass below the roller pair 131.

In addition, when the table for stacking 21 approaches to the rollerpair 131, the length of the separator S from a contact part of theroller pair 131 to the stacked body 500 becomes short. In the separatorconveying unit 12, the separator S can be pulled out from the separatorroll Sr but cannot be returned to the same. Therefore, the control unit5 controls the conveyance path adjustment unit 122 to move the movableroller 125 in the direction separating from the conveying roller 121, soas to adjust the length of the separator S.

In addition, the separator S is usually formed as a thin sheet. If thetension is low, it may be separated from the roller, and as a result, awrinkle or twist may occur. In addition, if the tension is too high, theseparator S may be torn or elongated. Therefore, the control unit 5adjusts the rotation speed of the traction roller 123 so that thetension of the separator S can be within a certain range.

The control unit 5 controls the position of the movable roller 125 andthe rotation speed of the traction roller 123. The conveyance pathadjustment unit 122 and the traction roller 123 are the conveyanceadjustment unit, while the position of the movable roller 125 and therotation speed of the traction roller 123 are the control condition. Thecontrol condition is stored in the storage circuit 52 in advance. Thecontrol unit 5 reads out the control condition from the storage circuit52, and controls the conveyance path adjustment unit 122 and thetraction roller 123 based on the control condition. Note that, as thecontrol unit 5 controls based on the control condition, the tension ofthe separator S is controlled to be within a certain range.

Further, the second claw part 23 moves to the one side Op via below theroller pair 131, and the separator S is bent at the second claw part 23.In this way, the separator S is folded at the positive electrode plate300 placed on the upper part of the stacked body 500 (see FIG. 19 ).

As the table for stacking 21 is further moved to the one side Op, thelength of the separator S from the nip of the roller pair 131 to thestacked body 500 is increased. In this case, the control unit 5 controlsthe movable roller 125 to approach the conveying roller 121 and adjuststhe rotation speed of the traction roller 123. In this case, theseparator S pulled out from the separator roll Sr is conveyed at apredetermined speed and is sent so that the tension can be within acertain range.

In addition, after the table for stacking 21 passes the roller pair 131,the roller pair 131 moves downward. In this way, also when the table forstacking 21 is at the first position P1, the separator S of the stackedbody 500 bent and folded at the second claw part 23 becomes horizontalor substantially horizontal (see FIG. 20 ). Further, the electrode plateEp to be the negative electrode plate 200 is conveyed to the upper partof the stacked body 500 placed on the upper part of the table forstacking 21 that has reached the first position P1.

After the electrode plate Ep to be the negative electrode plate 200 isplaced on the upper part of the separator S on the upper surface of thestacked body 500, and after the first claw part 22 presses the corner onthe other side Tp of the negative electrode plate 200, the second clawpart 23 is pulled out in the y direction and the z direction (FIG. 21 ).

By repeating the procedure described above, the stacked cell 400 can beformed, in which the separator S is folded in a bellows shape (folded inzigzag), and the negative electrode plates 200 and the positiveelectrode plates 300 are alternately disposed in the valley fold parts.In this way, the roller pair 131 is moved up and down in synchronizationwith the movement of the table for stacking 21, and hence theinclination of the separator S on the upper part of the stacked body 500can be reduced, so that the movement amount of the table for stacking 21can be suppressed.

Tension Control of Separator S

As described above, it is preferred that the tension of the separator Sis within a certain range. As described above, in the stacked cellmanufacturing device 100, based on the given control condition, thetension of the separator S when it is conveyed at a certain speed iscontrolled to be within a certain range. The stacked cell manufacturingdevice 100 may have an individual difference, or a variation incomposition of the separator S, and hence the tension may be varied evenif the same control condition is used for the control. Therefore, thecontrol unit 5 may have a learning mode for obtaining the controlcondition in the stacked cell manufacturing device 100.

The learning mode is described below with reference to the drawings.FIG. 22 is a flowchart illustrating operations in the learning mode.

The control unit 5 reads out given initial control condition Cnp fromthe storage circuit 52 (Step S301). Similarly to the control conditiondescribed above, the initial control condition Cnp is the condition todetermine the position of the movable roller 125 and the rotation speedof the traction roller 123. The initial control condition Cnp may beprovided in advance, or if the stacked cell manufacturing device 100 isoperated before, the stored control condition may be used as the initialcontrol condition Cnp. The initial control condition Cnp is preferablysuch a condition that the tension of the separator S does not become toohigh.

Further, the control unit 5 controls to convey the separator S at aconveyance speed Vt (Step S302). Note that the control unit 5 cancontrol the separator feed unit 1 to change the conveyance speed step bystep. When the learning mode is started, the conveyance speed Vt is setto the slowest speed of the conveyance speed that is set step by step.

The control unit 5 changes the initial control condition Cnp (StepS303). For instance, the position of the movable roller 125 is adjusted,or the rotation speed of the traction roller 123 is adjusted. In thiscase, the tension Ts of the separator S is measured by the tensionmeasuring unit 124 (Step S304).

The control unit 5 checks the tension Ts from the tension measuring unit124 and whether or not the tension is within a determined range (StepS305). If the tension Ts is not within the determined range (No in StepS305), the control unit 5 returns to the step for changing the initialcontrol condition Cnp (Step S303), and changes the initial controlcondition Cnp.

If the tension Ts is within the determined range (Yes in Step S305), thecontrol unit 5 determines whether or not the current conveyance speed Vtis a predetermined conveyance speed Vsh (Step S306). Note that theconveyance speed is changed step by step, and hence the conveyance speedVt is changed to be the predetermined conveyance speed Vsh. However, ifthe conveyance speed varies continuously, it may be possible todetermine whether or not the conveyance speed Vt has exceeded theconveyance speed Vsh in Step S305.

If the conveyance speed Vt is not the predetermined conveyance speed Vsh(No in Step S306), the control unit 5 increases the conveyance speed Vtby one step (Step S307), and restarts the operation with the newconveyance speed Vt (Step S302).

If the conveyance speed Vt becomes the predetermined conveyance speedVsh (Yes in Step S306), the control unit 5 sets the current initialcontrol condition Cnp to the control condition Cnt (Step S308). Further,the control unit 5 stores the control condition Cnt in the storagecircuit 52 (Step S309).

In this way, when the control unit 5 has the learning mode, it ispossible to use the control condition Cnt optimized for each stackedcell manufacturing device 100, and hence deterioration in accuracy ofthe stacked cell 400 can be suppressed.

Note that the learning mode may be executed when shipping the stackedcell manufacturing device 100, or when replacing the separator roll Sr,or when replacing a member such as the conveying roller 121. Inaddition, it may be executed when yield of the stacked cellmanufacturing device 100 is decreased. The learning mode may be readilyexecuted by a user, or may be executed only by a person who can performmaintenance.

Another example of the tension control of the separator S is describedwith reference to the drawings. FIG. 23 is a flowchart illustrating thetension control of the separator S.

In the tension control illustrated in FIG. 23 , the control unit 5obtains the tension Ts from the tension measuring unit 124 at everypredetermined timing (e.g., every certain period, every certain lengthof the fed separator S, or the like) (Step S401). The control unit 5stores the obtained tensions Ts in time series in the storage circuit 52(Step S402). The control unit 5 stores the tensions Ts and reads out acertain number of times of tensions Ts in the latest (Step S403). On thebasis of data of the read tensions Ts, the control unit 5 calculates areference value Sth (Step S404). The reference value Sth can be anarithmetic mean, a standard deviation, a moving average, or the like,but this is not a limitation.

The control unit 5 checks whether or not the reference value Sth issmaller than a maximum value St1 of a predetermined range (Step S405).If the reference value Sth is larger than the maximum value St1 (No inStep S405), the control unit 5 changes the control condition Cnt so thatthe reference value Sth becomes smaller the same (Step S406). Further,the control unit 5 returns to Step S401 and obtains the tension Ts.

If the reference value Sth is smaller than the maximum value St1 (Yes inStep S405), the control unit 5 checks whether or not the reference valueSth is larger than a minimum value St2 of the predetermined range (StepS407).

If the reference value Sth is larger than the minimum value St2 (Yes inStep S407), the control unit 5 returns to Step S401 without changing thecontrol condition, and obtains the tension Ts. If the reference valueSth is the minimum value St2 or smaller (No in Step S407), the controlunit 5 changes the control condition Cnt so that the reference value Sthbecomes larger than the same (Step S408). Further, the control unit 5returns to Step S401 and obtains the tension Ts.

In this way, the control unit 5 changes the control condition based onthe measured tensions Ts, and with this structure the stacked cellmanufacturing device 100 can stably produce the stacked cells. Inaddition, characteristics of the separator roll Sr may be differentbetween start and end of winding. By performing the tension controlbased on the measured tensions Ts, it is possible to cope with avariation in characteristics of the separator roll Sr.

Still another example of the tension control of the separator S isdescribed with reference to the drawings. FIG. 24 is a flowchartillustrating the tension control of the separator S.

In the tension control illustrated in FIG. 24 , the control unit 5obtains the tension Ts from the tension measuring unit 124 at everypredetermined timing (e.g., every certain period, every certain lengthof the fed separator S, or the like) (Step S501).

The control unit 5 checks whether or not the tension Ts is smaller thana maximum value T1 of a predetermined range (Step S502). If the tensionTs is larger than the maximum value T1 (No in Step S502), the controlunit 5 changes the control condition Cnt so that the tension Ts becomessmaller than the same (Step S503). Further, the control unit 5 returnsto Step S501 and obtains the tension Ts.

If the tension Ts is smaller than the maximum value T1 (Yes in StepS502), the control unit 5 checks whether or not the tension Ts is largerthan a minimum value T2 of the predetermined range (Step S504).

If the tension Ts is larger than the minimum value T2 (Yes in StepS504), the control unit 5 returns to Step S501 without changing thecontrol condition and obtains the tension Ts. If the tension Ts is theminimum value T2 or smaller (No in Step S504), the control unit 5changes the control condition Cnt so that the tension Ts becomes largerthan the same (Step S505). Further, the control unit 5 returns to StepS501 and obtains the tension Ts.

The control unit 5 performs real time control using the current measuredtension Ts. Performing this real time control, it is possible topromptly cope with a malfunction of the device, or an emergent change ofthe separator S.

Separating Process of Stacked Cell

There is described a separating process to separate the stacked cell 400after completion of stacking from the separator S that is beingconveyed, with reference to the drawings. FIG. 25 is a flowchartillustrating the separating process of the stacked cell 400. FIG. 26 isa diagram illustrating a moved state of the separator holding unit 41after cutting. FIG. 27 is a diagram illustrating a state where theseparator S is passed from the separator holding unit 41 to the tablefor stacking 21. FIG. 28 is a diagram illustrating the table forstacking 21 that is moved to the first position P1.

In the stacked cell manufacturing device 100 described above, thestacked cell 400 is produced by the movement of the table for stacking21. The stacked cell 400 has the stacking structure as an example, inwhich the lowermost and uppermost layers are the negative electrodeplates 200, and the separator S is disposed under the lowermost negativeelectrode plate 200 and over the uppermost negative electrode plate 200.However, this stacking structure is not a limitation.

In addition, in the structure exemplified in FIG. 9 , the separator S isdisposed over the negative electrode plate 200 when the table forstacking 21 is at the second position P2. Therefore, when the table forstacking 21 is at the second position P2, the stacking of the stackedcell 400 is completed, but the stacking form is not limited to this.

The control unit 5 checks whether or not the stacking of the stackedbody 500 is completed when the table for stacking 21 is a the secondposition P2 (Step S601). The completion of the stacking of the stackedbody 500 can be checked, for example, based on the number ofreciprocating movements of the table for stacking 21, the conveyancelength of the separator S, or the like, but this is not a limitation. Ifthe stacking of the stacked body 500 is not completed (No in Step S601),the control unit 5 monitors the stacking of the stacked body 500 untilthe stacking of the stacked body 500 is completed (repeats Step S601).

When the stacking of the stacked body 500 is completed (Yes in StepS601), the control unit 5 sends an instruction to the stacked cellseparating unit 4 to move the separator holding unit 41 to the holdingposition Cc. As illustrated in FIG. 9 , the separator holding unit 41absorbs and holds the bottom surface of the separator S at the partbetween the roller pair 131 and the stacked body 500 (Step S602).

While the separator holding unit 41 holds the separator S, the part ofthe separator S between the separator holding unit 41 and the stackedbody 500 keeps a tension within a certain range. In this state, thecontrol unit 5 sends an instruction to the stacked cell separating unit4 to drive the separator cutting unit 42, and hence the separator S iscut at a part between the separator holding unit 41 and the table forstacking 21 (Step S603). Note that “at a part between the separatorholding unit 41 and the table for stacking 2” includes on the separatorholding unit 41. Therefore, “the separator S is cut at a part betweenthe separator holding unit 41 and the table for stacking 2” includesbeing cut on the separator holding unit 41.

As illustrated in FIG. 26 , the control unit 5 sends an instruction tothe stacked cell separating unit 4 to move the separator holding unit 41to the one side Op (Step S604). In addition, as illustrated in FIG. 26 ,the roller pair 131 is moved upward so that the table for stacking 21can move to the one side Op. The separator holding unit 41 is disposedat a position such that the table for stacking 21 can contact with theseparator S when the table for stacking 21 is moved to the one side Op.

The control unit 5 drives the stacked cell output unit 43 to take outthe stacked cell 400 on the table for stacking 21 (Step S605). After thestacked cell 400 is taken out, the control unit 5 moves the table forstacking 21 to the one side Op. Further, it passes the separator S fromthe separator holding unit 41 to the table for stacking 21 (Step S606).Further, as illustrated in FIG. 28 , when the table for stacking 21moves to the first position P1, the control unit 5 sends an instructionto the stacked cell separating unit 4 to move the separator holding unit41 to the standby position Es (Step S607).

As described above, the separator holding unit 41 holds the separator S,and hence the separator S can be securely cut. In addition, even if athin type of the separator S is used, as the leading end of the cutseparator S is held by the separator holding unit 41, movement of theleading end of the cut separator S can be controlled, and it can besecurely passed to the table for stacking 21.

Automatic Connection of Separator S

In the separator feed unit 1, the separators S pulled out from the twoseparator rolls Sr are fed to the connecting unit 14. Further, whenremaining amount of one of the separator rolls Sr becomes small, theconnecting unit 14 connects the rear end of the separator S pulled outfrom the one separator roll Sr to the leading end of the separator Spulled out from the other separator roll Sr.

In the stacked type battery Bp, if a joint part of the separator S isincluded in the stacked cell 400, it may cause a malfunction of thestacked cell 400, and it is preferred that the joint part is notincluded in the stacked cell 400. Therefore, the stacked cellmanufacturing device 100 adopts a method for excluding the joint partfrom the stacked cell 400 when the separators S are connected.Hereinafter, connection of the separators S is described with referenceto the drawings. FIG. 29 is a flowchart illustrating the connectingoperation of the separators S.

The control unit 5 detects the remaining amount of the separator S fromthe separator remaining amount detector 111. The control unit 5 checkswhether or not the remaining amount of the separator roll Sr from whichthe separator S is currently pulled out is less than a certain amount,from the separator remaining amount detector 111 (Step S701). If theremaining amount of the separator roll Sr is the certain amount or more(No in Step S701), it obtains the remaining amount of the separator rollSr (repeats Step S701).

If the remaining amount of the separator roll Sr becomes less than thecertain amount (Yes in Step S701), the control unit 5 obtains thecurrent number of stacked layers in the stacked body 500 (Step S702).Further, the control unit 5 calculates length of the separator Snecessary for completing the stacked cell 400 (Step S703).

The control unit 5 checks whether or not the length of the separator Snecessary for completing the stacked cell 400 is longer than the pathfrom the stacked body 500 to the connecting unit 14 (Step S704). If thelength of the separator S necessary for completing the stacked cell 400is longer than the path from the stacked body 500 to the connecting unit14 (Yes in Step S704), the process returns to Step S702.

If the length of the separator S necessary for completing the stackedcell 400 is shorter than the path from the stacked body 500 to theconnecting unit 14 (No in Step S704), the control unit 5 sends aninstruction to the connecting unit 14 to cut the currently conveyedseparator S, and to connect it to the separator S pulled out from theremaining separator roll Sr (Step S705).

The control unit 5 checks whether or not the stacked cell 400 iscompleted and is taken out (Step S706). The control unit 5 waits untilthe stacked cell 400 is taken out (If No in Step S706, Step S706 isrepeated). If the stacked cell 400 is taken out (Yes in Step S706), thecontrol unit 5 stops the electrode feed unit 3, and drives the separatorfeed unit 1 and the folding unit 2, so as to make a folded body of onlythe separator S folded in a bellows shape (Step S707).

Every time when the table for stacking 21 moves to and fro, the controlunit 5 manages whether or not the joint part of the separator S isincluded in the folded body based on the length of the separator S (StepS708). The control unit 5 waits until the joint part of the separator Sis included in the folded body (If No in Step S708, Step S708 isrepeated). Further, if the joint part is included in the folded body(Yes in Step S708), the control unit 5 sends an instruction to thestacked cell separating unit 4 to cut the separator S (Step S709).Further, the folded body on the table for stacking 21 is discarded (StepS710).

By connecting the separator S as described above, the separator roll Srfrom which the separator S is pulled out can be securely switched, andaccuracy of the stacked cell 400 can be maintained.

Although the embodiment of the present invention is described above, thepresent invention is not limited to this description. In addition, theembodiment of the present invention can be variously modified withoutdeviating from the spirit of the invention.

LIST OF REFERENCE SIGNS

100 manufacturing device

200 negative electrode plate

201 terminal part

300 positive electrode plate

301 terminal part

400 stacked cell

500 stacked body

1 separator feed unit

2 folding unit

3 electrode feed unit

4 stacked cell separating unit

5 control unit

11 separator roll attachment unit

111 separator remaining amount detector

12 separator conveying unit

121 conveying roller

122 conveyance path adjustment unit

123 traction roller

124 tension measuring unit

125 movable roller

13 separator roller

131 roller pair

14 connecting unit

21 table for stacking

211 table moving unit for stacking

22 first claw part

23 second claw part

24 imaging unit for checking

24N imaging unit for checking

24P imaging unit for checking

30 electrode plate feed unit

30N electrode plate feed unit

30P electrode plate feed unit

31 standby table

32 position adjusting table

33 conveying unit

331 first conveying unit

332 second conveying unit

333 connecting arm

34 imaging unit for adjustment

35 conductive sheet conveying unit

351 conductive sheet roll attachment unit

36 electrode cutting unit

361 fixed blade

3611 fixed cutting blade

362 rotary blade

3621 rotary cutting blade

363 rotary blade moving unit

364 first conveying roller unit

3641 lower roller

3642 upper roller

365 second conveying roller unit

3651 lower roller

3652 upper roller

366, 367, 368 conveying roller unit

37 notch forming unit

371 notching mold

372 edge detector

373 mold moving unit

374 die

375 punch

381 conveyor

382 cleaner

41 separator holding unit

42 separator cutting unit

43 stacked cell output unit

51 processing circuit

52 storage circuit

Ag corner

Bp stacked type battery

Cc holding position

Cnp initial control condition

Cnt control condition

Cp detection part

Cs case

Ct lid

Ep electrode plate

Epm protrusion

Es standby position

Nt notch

Op one side

P1 first position

P2 second position

1. An electrode cutting device arranged to cut a conductive sheet intoelectrode plates by a certain length, comprising: a fixed blade having afixed cutting blade extending in a direction crossing a conveyancedirection of a conductive sheet; and a rotary blade of a disk shapehaving a rotary cutting blade on the radial outer edge, wherein therotary blade is rotated and moved along the fixed blade.
 2. Theelectrode cutting device according to claim 1, wherein the rotary bladerotates and moves along the fixed blade in a state where it maintainscontact with the fixed blade.
 3. The electrode cutting device accordingto claim 2, wherein the rotary blade is applied with a force to presstoward the fixed blade.
 4. The electrode cutting device according toclaim 1, wherein a feed amount of the rotary blade with respect to thefixed blade and a rotation speed of the rotary blade are variable. 5.The electrode cutting device according to claim 1, wherein when cuttingof the conductive sheet is finished, the rotary blade is idled, and anidle rotation angle of the rotary blade is variable for every set numberof cutting.
 6. The electrode cutting device according to claim 1,further comprising a first conveying roller unit disposed on theupstream side of the rotary blade and the fixed blade in the conveyancedirection of the conductive sheet, and a second conveying roller unitdisposed on the downstream side of the same, wherein each of the firstconveying roller unit and the second conveying roller unit grabs theconductive sheet in the thickness direction, and applies a certaintension to the conveyed conductive sheet in the conveyance direction,and when cutting the conductive sheet by the rotary blade and the fixedblade, conveyance of the conductive sheet is stopped, and the tension ofthe conductive sheet at a part between the first conveying roller unitand the second conveying roller unit is varied with respect to theconveying tension.
 7. The electrode cutting device according to claim 6,wherein when cutting the conductive sheet, the first conveying rollerunit is stopped, and after a certain time elapses, the second conveyingroller unit is stopped.
 8. The electrode cutting device according toclaim 6, wherein when cutting the conductive sheet, the first conveyingroller unit and the second conveying roller unit are both stopped, andthen the second conveying roller unit is rotated by a certain amount inthe opposite direction to the conveyance direction of the conductivesheet.
 9. The electrode cutting device according to claim 1, furthercomprising: an electrode cutting unit arranged to cut the conductivesheet into the electrode plates by a certain length; and a notch formingunit arranged to form notches on both ends in the width direction of theconductive sheet, so as to support a part to be cut by the electrodecutting unit, wherein the notch forming unit includes a notching moldthat forms the notches in the conductive sheet and can move in the widthdirection, and an edge detector disposed on the upstream side of thenotching mold in the conveyance direction of the conductive sheet so asto detect an edge of the conductive sheet in the width direction, andthe notching mold is moved so that the notch is accurately formed at theedge of the conductive sheet in the width direction, based on the edgeof the conductive sheet detected by the edge detector.
 10. A stackedcell manufacturing device arranged to manufacture a stacked cell inwhich, electrode plates to be negative electrode plates and electrodeplates to be positive electrode plates are alternately disposed andstacked in valley fold parts of a bellows-shaped folded separator, thedevice comprising: a separator feed unit having a separator roller tofeed the separator in a tape shape; a folding unit arranged to fold theseparator fed from the separator roller in a bellows shape; and anelectrode feed unit arranged to feed the negative electrode plates andthe positive electrode plates alternately to the separator folded in thebellows shape by the folding unit, wherein the electrode feed unitincludes two electrode plate feed units, one of the electrode plate feedunits is disposed on one side so as to feed the electrode plate to bethe negative electrode plate, while the other electrode plate feed unitis disposed on the other side so as to feed the electrode plate to bethe positive electrode plate, each of the electrode plate feed unitsincludes an electrode cutting unit that cuts the conductive sheet intothe electrode plates by a certain length, and the electrode cutting unitincludes a fixed blade having a fixed cutting blade extending in adirection crossing a conveyance direction of the conductive sheet, arotary blade of a disk shape having a rotary cutting blade on the radialouter edge, and a rotary blade moving unit that rotates and moves therotary blade along the fixed cutting blade.
 11. The stacked cellmanufacturing device according to claim 10, wherein the rotary blademoving unit rotates and moves the rotary blade along the fixed cuttingblade in a state where contact between the rotary cutting blade and thefixed cutting blade is maintained.
 12. The stacked cell manufacturingdevice according to claim 11, further comprising a biasing unit thatapplies a force to press the rotary blade toward the fixed blade. 13.The stacked cell manufacturing device according to claim 10, wherein afeed amount of the rotary blade with respect to the fixed blade and arotation speed of the rotary blade are variable.
 14. The stacked cellmanufacturing device according to claim 10, wherein when cutting of theconductive sheet is finished, the rotary blade is idled, and an idlerotation angle of the rotary blade is variable for every set number ofcutting.
 15. The stacked cell manufacturing device according to claim10, wherein the electrode cutting unit includes a first conveying rollerunit disposed on the upstream side of the electrode cutting unit in theconveyance direction of the conductive sheet, and a second conveyingroller unit disposed on the downstream side of the same, each of thefirst conveying roller unit and the second conveying roller unit grabsthe conductive sheet in the thickness direction and applies a certaintension to the conveyed conductive sheet in the conveyance direction,and when cutting the conductive sheet, the electrode cutting unit stopsconveyance of the conductive sheet, and varies the tension of theconductive sheet at a part between the first conveying roller unit andthe second conveying roller unit with respect to the conveying tension.16. The stacked cell manufacturing device according to claim 15, whereinwhen cutting the conductive sheet, the electrode cutting unit stops thefirst conveying roller unit, and after a certain time elapses, it stopsthe second conveying roller unit.
 17. The stacked cell manufacturingdevice according to claim 15, wherein when cutting the conductive sheet,after both the first conveying roller unit and the second conveyingroller unit stop, the electrode cutting unit rotates the secondconveying roller unit by a certain amount in the opposite direction tothe conveyance direction of the conductive sheet.
 18. The stacked cellmanufacturing device according to claim 10, further comprising a notchforming unit arranged to form notches on both ends in the widthdirection of the conductive sheet, so as to support a part to be cut bythe electrode cutting unit, wherein the notch forming unit includes anotching mold that forms the notches in the conductive sheet and canmove in the width direction, and an edge detector disposed on theupstream side of the notching mold in the conveyance direction of theconductive sheet so as to detect an edge of the conductive sheet in thewidth direction, and the notching mold is moved so that the notch isaccurately formed at the edge of the conductive sheet in the widthdirection, based on the edge of the conductive sheet detected by theedge detector.